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We used spray red insulating varnish on my neighbor's 8/1 crankcase interior and access door interiors after we ground it smooth- same stuff as Glyptol and a whole lot cheaper. I think it was 38ac who tipped me off on that...much appreciated.

Much appreciated. Glyptal is running about $40.00 delivered were as the generic is about $12.00. I was all prepared to buy Glyptal if if was superior. I don't want to cheap-out on my gen build but it looks like the generic will do...Thanks again BruceM

I've got a fair amount of surface rust inside my ST head. Do I need to sand it like I was refinishing a car or just get it fairly smooth and clean?

I'd only give the stator a light cleanup. Might be a good place for some spray electrical varnish, but sometimes finishes aren't helpful regarding rust. I live in a desert climate so rust is a non-issue here; hopefully someone else from a more corrosive environment might chime in on this.

Most of the "insulating varnish" I've seen and used has had an epoxy binder... very strong and lasting results. No particular needs for name-brand Glyptol.

I would wipe the rust where possible with clean rags and blow dry with dry air-pressure... but the generator innards are no place for much messing about! It only takes a very small insulation flaw in one of your windings to start big trouble and possible failure.

The insulating varnish product I use comes from WW Grainger and is called Spray On. It has worked well both for it's stated purpose and to seal up the insides of the various 'roids that have been through the shop.